Positive Displacement Sorter With Rotational Diagonal Discharge
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Solution Overview
Problem
Existing parallel sorters face issues with article orientation mismatch between the conveying surface and take-away lanes, leading to jams due to articles not aligning properly with angled lanes, especially when making turns.
Innovation Solution
A positive displacement sorter with a rotational system comprising a first and second portion of the conveying surface, where the first portion has angled rollers biasing articles toward the second portion with higher friction, allowing efficient rotation of the leading article portion into the take-away lane.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If articles are diverted parallel to the conveying surface using pusher shoes, then diverting efficiency is improved, but article orientation mismatch occurs between the conveying surface and take-away lanes
Solution Approach 1:
The take-away lane is segmented into a first portion and a second portion. The first portion receives articles at an angle from the conveying surface, while the second portion orients articles perpendicular to the conveying surface direction, allowing separate optimization of each segment for its specific function
Solution Approach 2:
The system transitions from parallel diverting (articles moving in the same direction as the conveying surface) to diagonal diverting by orienting the take-away lane at an angle, adding a dimensional component to the article transfer path that resolves the orientation mismatch
2Productivity
If take-away lanes are oriented at an angle from the conveying surface, then article flow direction is improved, but article jams occur between the conveying surface and take-away lanes
Solution Approach 1:
The rotational system performs preliminary rotation of articles on the take-away lane before they enter the angled section. By pre-orienting articles to match the take-away lane angle, the system prevents jams from occurring at the junction between the conveying surface and take-away lane
Solution Approach 2:
The rotational system acts as an intermediary between the parallel diverting mechanism and the angled take-away lane. It mediates the orientation transition, ensuring articles are properly aligned before entering the angled section, thus preventing jams
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The rotational system ensures articles are aligned correctly with the take-away lane, reducing jams and enhancing operational efficiency by allowing articles to be diverted sooner without trailing portions lagging, thus improving sorter performance.
Implementation Method 1
The second portion may have a surface with a higher friction than the first portion. The second portion may be a high-friction belt or a plurality of high-friction parallel rollers.
Implementation Method 2
The second portion may have a surface with a higher friction than the first portion. The second portion may be a high-friction belt or a plurality of high-friction parallel rollers.
Data Source
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AI summary
A positive displacement sorter and method of diverting articles includes a conveying surface to convey articles in a longitudinal direction and at least one diagonal takeaway lane extending diagonally from the conveying surface to receive articles being diverted from the conveying surface. The sorter includes plurality of pushers to move together in a lateral direction to displace an item on the conveying surface to the diagonal takeaway lane and a rotational system to rotate a leading portion of a diverted article in the direction of the takeaway lane. The rotational system may be a portion of the takeaway lane including a conveying surface having a first portion of rollers and a second portion of rollers. The first portion of rollers direct a diverted article toward the second portion of rollers and the second portion of rollers convey the diverted article in the direction of the takeaway lane.